Solar module having a plurality of strings configured from a five strip cell

ABSTRACT

In an example, the present invention provides a method of manufacturing a solar module. The method includes providing a substrate member having a surface region, the surface region comprising a spatial region, a first end strip comprising a first edge region and a first interior region, the first interior region comprising a first bus bar, a plurality of strips, a second end strip comprising a second edge region and a second interior region, the second edge region comprising a second bus bar, the first end strip, the plurality of strips, and the second end strip arranged in parallel to each other and occupying the spatial region such that the first end strip, the second end strip, and the plurality of strips consists of a total number of five (5) strips. The method includes separating each of the plurality of strips, arranging the plurality of strips in a string configuration, and using the string in the solar module.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a divisional of U.S. Ser. No.15/611,714, filed Jun. 1, 2017, which claims priority to U.S.Provisional No. 62/349,535, filed Jun. 13, 2016, and is also acontinuation-in-part of U.S. Ser. No. 14/609,307, filed Jan. 29, 2015,which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

The present invention is directed to photovoltaic systems andmanufacturing processes and apparatus thereof. In particular, thepresent invention provides an apparatus and method for a high-densitysolar module.

As the population of the world has increased, industrial expansion hasled to a corresponding increased consumption of energy. Energy oftencomes from fossil fuels, including coal and oil, hydroelectric plants,nuclear sources, and others. As merely an example, the InternationalEnergy Agency projects further increases in oil consumption, withdeveloping nations such as China and India accounting for most of theincrease. Almost every element of our daily lives depends, in part, onoil, which is becoming increasingly scarce. As time further progresses,an era of “cheap” and plentiful oil is coming to an end. Accordingly,other and alternative sources of energy have been developed.

In addition to oil, we have also relied upon other very useful sourcesof energy such as hydroelectric, nuclear, and the like to provide ourelectricity needs. As an example, most of our conventional electricityrequirements for home and business use comes from turbines run on coalor other forms of fossil fuel, nuclear power generation plants, andhydroelectric plants, as well as other forms of renewable energy. Oftentimes, home and business use of electrical power has been stable andwidespread.

Most importantly, much if not all of the useful energy found on theEarth comes from our sun. Generally all common plant life on the Earthachieves life using photosynthesis processes from sunlight. Fossil fuelssuch as oil were also developed from biological materials derived fromenergy associated with the sun. For human beings including “sunworshipers,” sunlight has been essential. For life on the planet Earth,the sun has been our most important energy source and fuel for modernday solar energy.

Solar energy possesses many desirable characteristics; it is renewable,clean, abundant, and often widespread. Certain technologies developedoften capture solar energy, concentrate it, store it, and convert itinto other useful forms of energy.

Solar panels have been developed to convert sunlight into energy. Forexample, solar thermal panels are used to convert electromagneticradiation from the sun into thermal energy for heating homes, runningcertain industrial processes, or driving high-grade turbines to generateelectricity. As another example, solar photovoltaic panels are used toconvert sunlight directly into electricity for a variety ofapplications. Solar panels are generally composed of an array of solarcells, which are interconnected to each other. The cells are oftenarranged in series and/or parallel groups of cells in series.Accordingly, solar panels have great potential to benefit our nation,security, and human users. They can even diversify our energyrequirements and reduce the world's dependence on oil and otherpotentially detrimental sources of energy.

Although solar panels have been used successfully for certainapplications, there are still certain limitations. Solar cells are oftencostly. Depending upon the geographic region, there are often financialsubsidies from governmental entities for purchasing solar panels, whichoften cannot compete with the direct purchase of electricity from publicpower companies. Additionally, the panels are often composed of costlyphotovoltaic silicon bearing wafer materials, which are often difficultto manufacture efficiently on a large scale, and sources can be limited.

Therefore, it is desirable to have novel system and method formanufacturing solar panels.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to photovoltaic systems andmanufacturing processes and apparatus thereof. In particular, thepresent invention provides an apparatus and method for using diodeprotection for a high-density solar module. In an example, the presentmethod uses one of three inner strips separated from a photovoltaicmaterial while two other strips are not included. There are otherembodiments as well.

In an example, the present invention provides a method of manufacturinga solar module. The method includes providing a substrate member havinga surface region, the surface region comprising a spatial region, afirst end strip comprising a first edge region and a first interiorregion, the first interior region comprising a first bus bar, aplurality of strips, a second end strip comprising a second edge regionand a second interior region, the second edge region comprising a secondbus bar, the first end strip, the plurality of strips, and the secondend strip arranged in parallel to each other and occupying the spatialregion such that the first end strip, the second end strip, and theplurality of strips consists of a total number of five (5) strips. Themethod includes separating each of the plurality of strips, arrangingthe plurality of strips in a string configuration, and using the stringin the solar module.

In an example, a solar module apparatus is provided. The apparatus has aplurality of strings, each of the plurality of strings being configuredin a parallel electrical arrangement with each other and a plurality ofphotovoltaic strips forming each of the plurality of photovoltaicstrings. The apparatus has a first end termination configured along afirst end of each of the plurality of strings and a second endtermination configured along a second end of each of the plurality ofstrings. The module has an equivalent diode device configured betweenthe first end termination and the second end termination such that oneof the plurality of photovoltaic strips associated with one of theplurality of strings when shaded causes the plurality of strips (“ShadedStrips”) associated with the one of the strings to cease generatingelectrical current from application of electromagnetic radiation, whilea remaining plurality of strips, associated with the remaining pluralityof strings, each of which generates a current that is substantiallyequivalent as an electrical current while the Shaded Strips are notshaded, and the equivalent diode device between the first terminal andthe second terminal for the plurality of strips is configured to turn-onto by-pass electrical current through the equivalent diode device suchthat the electrical current that was by-passed traverses the equivalentdiode device coupled to the plurality of strips that are configuredparallel to each other. In an example, whereupon each of the pluralityof strips has an aperture region and has been derived from one of threeinner strips configured from and separated from a photovoltaic substratemember, while a pair of other strips are not included.

Many benefits can be achieved by ways of the present invention. As anexample, the present module can be made using conventional process andmaterials. Additionally, the present module is more efficient thanconventional module designs. Furthermore, the present module, andrelated techniques provides for a more efficient module usage usingby-pass diodes configured with multiple zones of solar cells. Dependingupon the example, there are other benefits as well.

A further understanding of the nature and advantages of the presentinvention may be realized by reference to the remaining portions of thespecification and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a solar cell article according toan example of the present;

FIG. 2 is a front view thereof;

FIG. 3 is a back view thereof;

FIG. 4 is a top view thereof;

FIG. 5 is a bottom view thereof;

FIG. 6 is a first side view thereof;

FIG. 7 is a second side view thereof;

FIGS. 8-12 are illustrations of an edge photovoltaic strip according toan example of the present invention;

FIGS. 13-17 are illustrations of a center photovoltaic strip accordingto an example of the present invention;

FIGS. 18A and 18B-20 illustrate a photovoltaic strip according to anexample of the present invention;

FIGS. 21-25 illustrate a solar module according to an example of thepresent invention;

FIG. 26 is a front view of a solar cell in an example of the presentinvention;

FIG. 27 is a side view of the solar cell, including bus bars, in anexample of the present invention;

FIG. 28 is an expanded view of a bus bar in an example of the presentinvention;

FIGS. 29-33 illustrate a solar cell under a cut and separation processaccording to an example of the present invention;

FIG. 34 is a top view of a photovoltaic string according to an exampleof the present invention;

FIG. 35 is a side view of the photovoltaic string according to anexample of the present invention; and

FIG. 36 is a simplified diagram of a simplified system diagram accordingto an example of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to photovoltaic systems andmanufacturing processes and apparatus thereof. There are otherembodiments as well.

Embodiments of the present invention provide system and methods formanufacturing high density solar panels. Embodiments of the presentinvention use overlapped or tiled photovoltaic strip elements toincrease the amount of photovoltaic material, thereby increasing anamount of power, while reducing an amount of series resistance losses inthe solar panel. It is noted that specific embodiments are shown forillustrative purposes, and represent examples. One skilled in the artwould recognize other variations, modifications, and alternatives.

Although orientation is not a part of the invention, it is convenient torecognize that a solar module has a side that faces the sun when themodule is in use, and an opposite side that faces away from the sun.Although, the module can exist in any orientation, it is convenient torefer to an orientation where “upper” or “top” refer to the sun-facingside and “lower” or “bottom” refer to the opposite side. Thus an elementthat is said to overlie another element will be closer to the “upper”side than the element it overlies.

FIG. 1 is a front perspective view of a solar cell article according toan example of the present. This diagram is merely an example, and shouldnot unduly limit the scope of the claims herein. One of ordinary skillin the art would recognize other variations, modifications, andalternatives. FIG. 2 is a front view thereof. FIG. 3 is a back viewthereof. FIG. 4 is a top view thereof. FIG. 5 is a bottom view thereof.FIG. 6 is a first side view thereof. FIG. 7 is a second side viewthereof. A solar cell is shown. The solar cell has a substrate memberhaving a surface region. The surface region is an aperture regionexposing photovoltaic material. In an example, the photovoltaic materialcan be silicon, polycrystalline silicon single crystalline silicon, orother material.

In an example, the cell has the surface region comprising a spatialregion and a backside region. The cell has a first end strip comprisinga first edge region and a first interior region as provided on thespatial region. In an example, the first interior region comprising afirst bus bar, while the first edge region on the spatial region has nobus bar. In an example, the first end strip has an off cut on eachcorner. Each of the off cuts is about 45 degrees in angle, and has aflat edge abutting a pair of edges at ninety degrees from each other, asshown.

After the first bus bar, the solar cell has a plurality of strips areprovided on the spatial region. As show, each of the strips having a busbar along an edge furthest away from the first bus bar. Each of the busbars shown in FIG. 2 also include a scribe region adjacent to the busbar, and the scribe region is between the bus bar on the front side, anda bus bar on an adjacent strip on the backside, except for the pair ofbus bars on the front side between the fourth and fifth strips. Each ofthe strips is substantially rectangular in shape, and can be configuredwith edges at ninety degrees from each other.

In an example, the cell has a second end strip comprising a second edgeregion and a second interior region. In an example, the second interiorregion comprises a second bus bar such that the second bus bar and thebus bar from one of the plurality of strips forms a gap defining ascribe region. In an example, the second edge region comprises no busbar.

In an example, the first end strip, the plurality of strips, and thesecond end strip arranged in parallel to each other and occupying thespatial region such that the first end strip, the second end strip, andthe plurality of strips consists of a total number of five (5) strips.

In an example, the backside region comprises the second end stripcomprising the second edge region. In an example, the second edge regionhas a second backside bus bar such that the second backside bus bar andthe second bus bar are provided between photovoltaic material of thesecond end strip.

FIGS. 8-12 are illustrations of an edge photovoltaic strip according toan example of the present invention. As shown, a first end stripcomprising a first edge region and a first interior region as providedon the spatial region. In an example, the first interior regioncomprises a first bus bar, while the first edge region on the spatialregion has no bus bar. In an example, the first end strip comprises thefirst interior region and the first bus bar on the spatial region. Thefirst end strip further comprises a first scribe region provided inparallel to the first bus bar. In an example, the first end strip can besimilar to the last or second end strip. Referring to FIG. 9 , the firstend strip has a backside region, including bus bar. FIG. 10 illustratesa front view, while FIG. 11 illustrates a side view, and FIG. 12illustrates a back view of the first end strip. In an example, each busbar has a length (L) no greater than edge region, excluding the 45Degree corners. Of course, there can be other variations, modifications,and alternatives.

FIGS. 13-17 are illustrations of a center photovoltaic strip accordingto an example of the present invention. In an example, the stripnumbered 2 (e.g., FIGS. 13-17 ) comprises a second backside bus bar onthe backside region of the strip numbered 2. In an example, the secondbackside bus bar in parallel to the first bus bar, and having the firstscribe region defined between the first bus bar and the second backsidebus bar. Referring back to FIGS. 8-12 , the first end strip comprisesthe first edge region on the backside region. In an example, the firstedge region on the backside region comprises a first backside bus bar.In an example, the strip numbered 2 can be any interior strip such asthose numbered 3 and 4. In an example, each of the interior strips isrectangular in shape illustrating surface region and backside region. Inan example, each of the bus bars extends from a first end to a secondend of the surface region. Of course, there can be other variations,modifications, and alternatives.

FIGS. 18A and 18B-20 illustrate a photovoltaic string according to anexample of the present invention. In an example, each of the rectangularstrips is overlaid to form the string, as shown. The string comprisesseventeen strips arranged to form the string, although there can beother variations, modifications, and alternatives. FIG. 19 illustrates aback view of the string, and FIG. 20 illustrates a side view of thestring of FIGS. 18A and 18B.

FIGS. 21-25 illustrate a solar module according to an example of thepresent invention. As shown, FIG. 21 illustrates a front side of a solarmodule, and a side view is illustrated in FIG. 22 . A backside includingjunction box is shown in FIG. 23 .

FIG. 26 is a front view of a solar cell in an example of the presentinvention. In FIG. 26 , a solar feedstock device for a solar cell deviceis illustrated. In an example, the device has a silicon bearingsubstrate member having a surface region. The surface region comprises aspatial region, as shown in FIG. 26 . Now referring to FIG. 32 , thedevice has a backside region. The silicon bearing substrate membercomprises a thickness of photovoltaic material.

In an example, the feedstock device has a first end strip comprising afirst edge region and a first interior region as provided on the spatialregion. The first interior region comprises a first bus bar, while thefirst edge region on the spatial region has no bus bar. In an example, aplurality of strips as provided on the spatial region, each of thestrips having a bus bar along an edge furthest away from the first busbar, the plurality of strips being numbered from 2 to 4 from the firstend strip.

In an example, a second end strip comprising a second edge region and afifth interior region, the fifth interior region comprising a fifth busbar such that the fifth bus bar and a bus bar from one of the pluralityof strips numbered 4 forms a gap defining a scribe region. In anexample, the second edge region on the spatial region comprising no busbar.

In an example, the first end strip, the plurality of strips, and thesecond end strip are arranged in parallel to each other and occupyingthe spatial region such that the first end strip, the second end strip,and the plurality of strips consists of a total number of five (5)strips. In an example, the backside region comprises the second endstrip. In an example, the second end strip comprising the second edgeregion. The second edge region has a fifth backside bus bar provided onthe backside region.

In an example, a sixth bus formed on second edge region on the backsideregion of the second end strip. In an example, the first end strip, theplurality of strips, and the second end strip are arranged in parallelto each other and occupying the spatial region such that the first endstrip, the second end strip, and the plurality of strips consists of atotal number of five (5) strips. In an example, the backside regioncomprises the second end strip, the second end strip comprising thesecond edge region, the second edge region having the sixth backside busbar provided on the backside region. In an example, the backside regioncomprises the second end strip and the strip numbered 4 such that aportion of the backside region has no busbar structure as viewed fromthe backside region between the six bus bar and the fifth bus bar.

In an example, the first end strip comprises a bus bar on the backsideregion of the first edge region. In an example, the fifth bus bar andthe sixth bus bar have an equal length, such equal length is shorterthan any one of the bus bars among the plurality of strips.

In an example, the first end strip comprises the first interior regionand the first bus bar on the spatial region; and further comprising afirst scribe region is provided in parallel to the first bus bar; andwherein the strip numbered 2 comprises a second backside bus bar on thebackside region of the strip numbered 2, the second backside bus bar inparallel to the first bus bar, and having the first scribe regiondefined between the first bus bar and the second backside bus bar, thefirst end strip comprising the first edge region on the backside region,the first edge region on the backside region comprising a first backsidebus bar.

In an example, the strip numbered 2 comprises a second interior regionand a second bus bar on the spatial region; and further comprising asecond scribe region is provided in parallel to the second bus bar; andwherein the strip numbered 3 comprises a third backside bus bar on thebackside region of the strip numbered 3, the third backside bus bar inparallel to the second bus bar, and having the second scribe regiondefined between the second bus bar and the third backside bus bar.

In an example, the strip numbered 3 comprises a third interior regionand a third bus bar on the spatial region; and further comprising athird scribe region is provided in parallel to the second bus bar; andwherein the strip numbered 3 comprises a fourth backside bus bar on thebackside region of the strip numbered 3, the fourth backside bus bar inparallel to the third bus bar, and having the third scribe regiondefined between the third bus bar and the fourth backside bus bar.

In an example, the strip numbered 4 comprises a fourth interior regionand a fourth bus bar on the spatial region; and further comprising afourth scribe region is provided in parallel to the third bus bar; andwherein the strip numbered 4 comprises the fifth backside bus bar on thebackside region of the strip numbered 4, the fifth backside bus bar inparallel to the fourth bus bar, and having the fourth scribe regiondefined between the fourth bus bar and the fifth backside bus bar.

In an example, a backside spacing between the fourth backside bus barand the fifth backside bus bar is about two times a spacing between thefirst backside bus bar and the second backside bus bar.

In an example, the substrate member has a dimension of 156 mm and withinabout two mm. In an example, each of the strips has a desired width tobe assembled in the string configuration. In an example, the pluralityof strips are monolithically connected with each other. In an example,each of the plurality of strips has an aperture region. In an example,each of the plurality of strips has a width of 31.2 mm.

FIG. 27 is a side view of the solar cell, including bus bars, in anexample of the present invention. The side view has a thickness ofmaterial including a backside and a spatial region. A bus bar is alsoshown. FIG. 28 is an expanded view of a bus bar in an example of thepresent invention. As shown, FIG. 26 shows “PAIR” which is shown in anexploded view in FIG. 28 .

In an example, the present invention provides a method of manufacturinga solar module. The method includes providing a substrate member havinga surface region. In an example, the substrate is a solar cell asdescribed in the present specification. The solar cell is made ofphotovoltaic material, which has various features.

In an example, the surface region comprises a spatial region and abackside region, a first end strip comprising a first edge region and afirst interior region as provided on the spatial region. In an example,the first interior region comprises a first bus bar, while the firstedge region on the spatial region has no bus bar, and a plurality ofstrips as provided on the spatial region. In an example, each of thestrips has a bus bar along an edge furthest away from the first bus bar,a second end strip comprising a second edge region and a second interiorregion, the second interior region comprising a second bus bar such thatthe second bus bar and the bus bar from one of the plurality of stripsforms a gap defining a scribe region, the second edge region comprisingno bus bar, the first end strip, the plurality of strips, and the secondend strip arranged in parallel to each other and occupying the spatialregion such that the first end strip, the second end strip, and theplurality of strips consists of a total number of five (5) strips, thebackside region comprising the second end strip comprising the secondedge region, the second edge region having a second backside bus barsuch that the second backside bus bar and the second bus bar areprovided between photovoltaic material of the second end strip.

In an example, the method includes separating each of the plurality ofstrips. The method includes separating the first end strip, andseparating the second end strip by scribing via the scribe region andremoving the second end strip. Each of the separation processes canoccur along a spatial direction of the substrate.

In an example, the method includes transferring the first end strip in afirst magazine, transferring each of the plurality of strips into asecond magazine or a plurality of magazines, and transferring the secondend strip into a second magazine. In an example, the method includesselecting each of the plurality of strips, and arranging the pluralityof strips in a string configuration. The method then includes using thestring in the solar module.

In an example, the substrate member comprises a silicon material, thebackside region further comprising a first backside bus bar on the firstend strip, and a plurality of bus bars respectively formed on theplurality of strips.

In an example, the substrate member has a dimension of 156 mm and withinabout two mm, but can be others.

In an example, each of the strips has a desired width to be assembled inthe string configuration.

In an example, the plurality of strips are monolithically connected witheach other. In an example, each of the plurality of strips has anaperture region. Further details of the present invention can be foundthroughout the present specification and more particularly below.

FIGS. 29-33 illustrate a solar cell under a cut and separation processaccording to an example of the present invention. As shown, FIGS. 29 and30 show one of a plurality of scribe lines between each pair of strips.The scribe lines have been provided by a saw, laser cut, or otherseparation process. A backside and perspective view of the solar cellare shown in FIGS. 32 and 33 .

FIG. 34 is a top view of a photovoltaic string according to an exampleof the present invention. Each string has a plurality of strips arrangedin overlapping manner, as further illustrated below.

FIG. 35 is a side view of the photovoltaic string according to anexample of the present invention focused on a cell to cell overlap inthe string. As shown, a strip having a backside is overlapped with anedge of a surface of a strip, each of which is coupled using a bus bar,as shown.

FIG. 36 is a simplified diagram of a simplified system diagram accordingto an example of the present invention. Further details of the presentinvention can be found throughout the present specification and moreparticularly below.

In an example, the present method and system utilized a ⅕^(th) stripwidth versus ⅓^(rd), ¼^(th) or ⅙^(th) of a cell strip width based uponsome unexpected benefits and/or results, as shown in the table below.

PV Width Comment Width 78   52 39    31.2  26 mm Cell 4.5  3 2.25 1.8  1.5 Isc = 9A Current standard cell Fingers 80-200 80-150 80-120 80-10080 (Microns) Based on standard cell finger Shading  7.0%  5.8%  5.0% 4.5%   4% Finger shading Cell 98.7% 97.4% 96.2% 94.9% 93.6% 2 mmUtiliza- overlap tion Placements 2X 3X 4X 5X 6X Over standard moduleFill  76%  77%  78%  79%  79% Factor

In an example, the present strip has a width that is the size of the cutcell. In an example, current is directly proportional to the size of thestrip. Fingers have to carry current across the whole length of thestrip, while shading is the area of the strip shadowed by the fingers.In an example, cell utilization is the amount of cell area used foroverlapping versus active area. In an example, number of placements ishow many time as strip must be placed compared to a cell. In an example,fill factor is the efficiency of the cell versus is maximum powerproducing potential.

In an example, the purpose of designing a module to get the IVspecifications, as similar as a conventional module (Voc, Vmp, Isc, Imp,Power). In an example, the present method and designs (lower voltage,and higher current for the tracker application, higher voltage and lowercurrent for the residential module with module power electronics.

In an example, the present method and design uses a 31.2 mm strip width,which optimized the size as standard and module, as well as a currentand voltage similar to standard modules. This allowed the presentinvention to take advantage of standard inverters, electronics, andmechanical features.

The claims and drawings are focused on the interior strips. In anexample, each of the strings of strips can be made with the pseudosquare (exterior) strips as well.

In an example, in the table, it is demonstrated that going to smallerstrips provides higher efficiency. The marginal efficiency gains,however, decline as the strip width gets smaller. The difference betweena ⅕th strip from a cell and ⅙th strip from a cell in efficiency is verysmall. Smaller strips do come with other issues that make smaller stripsless attractive. In an example, smaller strips require more since thereare more of them. In particular, more strips are handled, and assembled.The manufacturing costs and equipment capex increase more than theefficiency gain is worth. In addition, smaller strips lead to more cellto cell overlap that uses up silicon. Having more cell to cell overlapsincreases the silicon cell usage and increased costs.

Most importantly, there are standard module sizes in solar industry thatare primarily dictated by the size of the photovoltaic cell. In anexample, sixty (60) cell modules are primarily used on roof-topapplications. Such sixty cell modules are typically about 1.6 m long by1 m wide in dimensions. Ground mount utility modules are typically 72cells and are almost 2 m long by 1 m wide in dimensions. For the presentmodule, it is desirable to maintain them within one of these formfactors. Almost every installer in the world has racking and mountinghardware designed around this basic size. Many have automatedengineering software for system design that also has these sizesembedded in them. Of course, there can be slight variations, althoughmaking the present module in the standard cell format is highly desired.

Still another feature relates to a open circuit voltage on a cold clearsunny day. Typically, solar module systems are rated for 600 VDC or 1000VDC. The system engineering, inverter designs, national electric codeare all standardized not to exceed one of these voltages. Theinstallation cost is highly influenced by the number of modules that canbe hooked up in series without exceeding the maximum voltage. As such,the present module electrical specification needs to be as similar aspossible to the industry standard modules (60 or 72) cell.

It has been discovered that ⅕th strip width is the best strip width tosimultaneously allow for the maximized performance, lowest manufacturingcosts, industry standard size, and industry standard electricalcharacteristics, each of which has been unexpected. The present ⅕ stripwidth is slightly larger in width than the conventional ⅙th stripwidths. The ⅕ strip width has higher assembly costs than the ⅙ stripwidth. Cell utilization will be less, however, the ⅕ strip widthperformance will be about the same. The ⅙ strip width module has amodule voltage that is about 20% higher causing higher installationcosts. In other examples, the ¼ cut strips will lose much of theefficiency gain associated with the ⅕th strip width and will be a muchhigher current and lower voltage module than is normal in the industry.There will be increased costs for handling the higher current includingthicker conductors, larger bypass diodes, and maybe a special junctionbox. The ⅕^(th) strip width is novel and benefits unexpected. Generallyall conventional modules use ⅙th strip width. It would be great if wecould lock up ⅕th strip width. Of course, there can be other variations,modifications, and alternatives.

This application is also related to U.S. Ser. No. 14/869,130 filed Sep.29, 2015, titled SOLAR MODULE WITH DIODE DEVICE FOR SHADING, in the nameof Kevin R. Gibson, which is hereby incorporated by reference in itsentirety for all purposes.

While the above is a complete description of specific embodiments of theinvention, the above description should not be taken as limiting thescope of the invention as defined by the claims.

The invention claimed is:
 1. A method of manufacturing a solar modulecomprising: providing a substrate member having a surface region, thesurface region comprising a spatial region and a backside region, afirst end strip comprising a first edge region and a first interiorregion as provided on the spatial region, the first interior regioncomprising a first bus bar, while the first edge region on the spatialregion has no bus bar, a plurality of strips as provided on the spatialregion, each of the strips having a bus bar along an edge furthest awayfrom the first bus bar, a second end strip comprising a second edgeregion and a second interior region, the second interior regioncomprising a second bus bar such that the second bus bar and the bus barfrom one of the plurality of strips forms a gap defining a scriberegion, the second edge region comprising no bus bar, the first endstrip, the plurality of strips, and the second end strip arranged inparallel to each other and occupying the spatial region such that thefirst end strip, the second end strip, and the plurality of stripsconsists of a total number of five (5) strips, the backside regioncomprising the second end strip comprising the second edge region, thesecond edge region having a second backside bus bar; separating each ofthe plurality of strips; separating the first end strip; separating thesecond end strip by scribing via the scribe region and removing thesecond end strip; transferring the first end strip in a first magazine,transferring each of the plurality of strips into a second magazine or aplurality of magazines; transferring the second end strip into a secondmagazine; selecting each of the plurality of strips; arranging theplurality of strips in a string configuration; using the string in thesolar module.
 2. The method of claim 1 wherein the substrate membercomprises a silicon material, the backside region further comprising afirst backside bus bar on the first end strip, and a plurality of busbars respectively formed on the plurality of strips.
 3. The method ofclaim 1 wherein the substrate member has a dimension of 156 mm andwithin about two mm.
 4. The method of claim 1 wherein each of the stripshas a desired width to be assembled in the string configuration.
 5. Themethod of claim 1 wherein the plurality of strips are monolithicallyconnected with each other.
 6. The method of claim 1 wherein each of theplurality of strips has an aperture region.